Architectural column and method and apparatus for production

ABSTRACT

A column comprising courses of building blocks such as bricks is arranged with the long axis of each block parallel to the axis of the column and filled with a substrate such as concrete with an axial structural member. The column may be produced with the aid of a cage including spaced apart hoops or rings used to position blocks during column construction. The cage includes indenters for offsetting some of the blocks in order to form aesthetically pleasing grooving along the finished column.

FIELD OF THE INVENTION

[0001] This invention relates to columns for buildings. This inventionalso extends to an apparatus for use in making the columns for buildingsand also to a method of making the columns using the apparatus.

[0002] This invention relates particularly but not exclusively to anapparatus and method for making building columns for residential homesthat exhibit highly aesthetic and stylish features. It will therefore beconvenient to hereinafter describe the invention with reference to thisexample application. However it is to be clearly understood that theinvention is capable of broader application.

BACKGROUND OF THE INVENTION

[0003] Simulated decorative columns or pillars are well known in thepoor art. For example in US Pat. No. 5,568,709 there is described acolumn comprising an axial member surrounded by a jacket composed of aplurality of wedge shaped elongated rigid foam members. Upon assemblingthe jacket around the axial member the outer surface of the jacket issanded to provide a smooth surface and the smooth surface is providedwith an overcoating resembling a cut surface of stone. A problem withthis system is that the columns are not particularly sturdy orweatherproof, composed as they are of foam, so that their longevity islimited. Furthermore a special manufacturing process is required toproduce the columns prior to their transportation to the site where theyare to be installed.

[0004] Alternatively in US Pat. No. 5,934,035 there is described amodular column of rectangular cross section assembled by overlayingprecast brick layers, one on top of the other to form a column. Aproblem with this column and system of construction is that it is notaesthetically pleasing as the resulting column has an appearancesomewhat similar to that of a typical rectangular brick chimney stack.

[0005] Traditionally columns have been produced of circular stonecross-sections stacked upon each other. While columns produced by such amethod are regarded as being aesthetically pleasing, they are expensiveand difficult to construct.

[0006] It is an object of the invention to provide a column whichovercomes at least some of the problems of those described in the priorart and to provide a useful alternative to known column structures andmethods of forming same.

SUMMARY OF THE INVENTION

[0007] In the following description and claims the term “block” is to beunderstood as including any building component suitable for theconstruction of a column of the type described herein. Accordingly, andwithout limitation, the term “block” refers at least to a brick,including a glass brick, a tile or a stone slab such as a marble slab.Furthermore the term “wedge” is to be understood to encompasstrapezoidal shapes and generally will not taper to a point at one end.

[0008] According to a first aspect of the invention there is provided acolumn including blocks, wherein the longest dimension of each block isarranged parallel to the axis of the column.

[0009] Preferably the blocks are formed in courses with one course ontop of another.

[0010] In one embodiment the courses are of square or rectangular crosssection. In another embodiment the courses may include wedge-shapedcomponents positioned alternatively between the blocks in order to formcourses of generally circular cross section. Alternatively the columnmay be comprised entirely of the wedge-shaped components. Thewedge-shaped components are typically of the same material as theblocks.

[0011] Usually the column has an axial structural member which thecourses surround. Typically the interior of the column is filled with asettable material, eg concrete.

[0012] The wedge shaped components may be inwardly offset from adjacentblocks in order to form longitudinal channels along the outside of thecolumn. Alternatively the wedge shaped components may be located so thattheir outer surface is adjacent that of neighbouring blocks therebyforming a column with smooth sides.

[0013] If it is desired a render may be applied to the finished column,

[0014] The column may further include a base and a head.

[0015] The column may have a uniform cross-section along its length.Alternatively it may have a non-uniform cross-section along its length,eg with a tapering profile.

[0016] According to a further aspect of the present invention there isprovided a column formation apparatus or “cage” for facilitatingproduction of the previously described column including a number offirst retaining members interconnected by a number of longitudinalmembers arranged transversely relative to said first retaining members.

[0017] Preferably the first retaining members are rings. Preferably therings include opening and closing means The opening and closing meansare conveniently provided by at least one hinge and flanges which may besecured together, for example by bolting or clipping. Other opening andclosing means are also possible however, for example rather than use ahinge a further flange and bolt arrangement could be provided.

[0018] Preferably the longitudinal members are comprised of metal rodsattached to the rings.

[0019] In one form the longitudinal members may be attached to the innerwalls of the rings. In that case the longitudinal members may act asindenters during construction of a column by means of the cage. Forexample, the metal rods could be aluminium or steel rods of square crosssection. Alternatively the longitudinal members could be attached to theouter walls of the rings with separate indenters attached around theinner wall of each ring.

[0020] The column formation apparatus may include a stabilising meansfor securing to the axial structural member of the column. Such a meanswill typically be a metal member extending from a ring to the axialmember and boltable or otherwise attachable to the axial member.

[0021] In order to form columns of a generally circular cross sectionthe rings will also be circular. Alternatively columns of other crosssections, such as rectangular, may be formed by means of a cage havingretaining members of corresponding cross-sections.

[0022] Preferably the rings are spaced apart no further than the longdimension of the building components used to produce a column.

[0023] In a preferred embodiment the column formation apparatus isconfigured to allow adjustment of the spacing between rings along thelongitudinal members.

[0024] Preferably the indenters are also adjustable so that the depth ofoffset may be varied.

[0025] According to yet a further aspect of the invention there isprovided a method of forming a column as described above, the methodcomprising the steps of:

[0026] forming closed courses of blocks on top of each other wherein thelong dimension of each of the blocks is parallel to the axis of thecolumn to be formed;

[0027] upon completion of each course filling the space defined by thatcourse with a substrate such as concrete.

[0028] Preferably the method is performed with the aid of a cage aspreviously described and includes the steps of:

[0029] locating the cage in a position where a column is to be formed;

[0030] arranging building components such as blocks and/or wedgesagainst the inner limits of the cage, the longest dimension of thebuilding components being orientated parallel to the axis of the column;and

[0031] mortaring adjacent building components to each other during thearrangement step.

[0032] Preferably the step of locating the cage includes locating thecage about an axial structural member for the column by opening therings and placing the cage around said member.

[0033] Alternatively the cage may be lowered over the axial structuralmember.

[0034] The cage may be stabilised by securing it to said structuralmember.

[0035] If the hoops are of a circular shape then the arranging of thebuilding components will include positioning wedges and blocks adjacenteach other in order to form courses of generally circular cross section.If the cage is of the type wherein the longitudinal members are fixed tothe internal walls of the hoops then the arrangement step will producelongitudinal channels due to indentation of some of the components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] An apparatus for making building columns in accordance with theinvention and the columns produced thereby may manifest themselves in avariety of forms. It will be convenient to hereinafter describe indetail several preferred embodiments of the invention with reference tothe accompanying drawings. The purpose of providing this detaileddescription is to instruct persons having an interest in the subjectmatter of the invention how to carry the invention into practicaleffect. It will be clearly understood that the specific nature of thisdetailed description does not supersede the generality of the precedingbroad description. In the drawings:

[0037]FIG. 1 is a perspective view of a column formed in accordance withthe present invention;

[0038]FIG. 1A is a perspective view of a block, being a brick, used inthe formation of the column of FIG. 1;

[0039]FIG. 1B is a perspective view of a further block, being a wedge,used in the formation of the column of FIG. 1;

[0040]FIG. 2 is a cross-section through a column similar to that of FIG.1 and in accordance with the present invention;

[0041]FIG. 3 is a simplified perspective view of a cage in accordancewith a first embodiment of the invention used in the production of thecolumn of FIG. 1 in which for ease of clarity some of the longitudinalmembers have been omitted;

[0042]FIG. 4 is a plan view of a hoop or ring of the cage of FIG. 3;

[0043]FIG. 5 is a plan view of the hoop or ring of FIG. 4 in placearound a column;

[0044]FIG. 5A is a plan view of a hoop or ring similar to that of FIG. 4wherein the longitudinal members are of a size facilitating placement ofwedges against the inner periphery of each ring;

[0045]FIG. 6 is a perspective view of a cage according to a furtherembodiment of the invention;

[0046]FIG. 7 is a plan view of a cage according to yet a furtherembodiment of the invention;

[0047]FIG. 8 is a close-up of part of the cage of FIG. 7 showing detailsof the attachment of longitudinal members to the ring and also indentersfor indenting the blocks;

[0048]FIG. 9 is a perspective view of a longitudinal member of the cageof FIG. 7;

[0049]FIG. 10 is a perspective view showing detail of part of the cageof FIG. 7;

[0050]FIG. 11 is a perspective view of a portion of a ring of the cageof FIG. 7;

[0051]FIG. 12 is a simplified perspective view of a cage used in theproduction of a column of non-uniform cross-section;

[0052]FIG. 13 is a perspective view of a column in accordance withanother embodiment of the invention also for making a column ofnon-uniform cross-section;

[0053]FIGS. 14A and 14B are perspective views of another embodiment of acage for making a column of constant cross-section along its length withsome detail omitted for clarity;

[0054]FIG. 15 is a perspective view showing part of a ring of the cageof FIG. 14;

[0055]FIG. 16 is an exploded perspective view of an apparatus forshaping blocks for a tapering column prior to their insertion into thecage of FIGS. 12 and 13;

[0056]FIG. 17 is a perspective view of a block clamped into theapparatus of FIG. 16 with a sanding tool positioned above the block forremoving material from the block so as to provide one side of the blockwith the appropriate contoured profile;

[0057]FIG. 18 is a perspective view of the apparatus of FIG. 16 showinga block that has been shaped to give a tapering profile for a column ofvarying cross-section; and

[0058]FIG. 19 is a perspective view from one end of a block andapparatus similar to that in FIG. 16.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0059] Referring now to FIG. 1, there is depicted a column indicatedgenerally by the reference numeral 10.

[0060] Column 10 is composed of a number of courses of blocks on top ofeach other with their long dimensions vertical and parallel to thelongitudinal axis of the column. FIG. 2 shows a plan view of a singlecourse 12. It will be noted that between rectangular blocks 2 are wedgeblocks 4 formed by cutting square rectangular standard blocks in theappropriate fashion. For example ceramic bricks may be cut with adiamond-saw, so that they have a trapezoidal cross-section.

[0061] A building material which is particularly convenient to use inthe formation of columns of the type discussed herein is AutoclavedAerated Concrete such is as available under the trade mark HEBELmanufactured in Australia by CSR Limited of 9 Help Street Chatswood, NSW2067, Australia. This material is considerably lighter than bricks orother masonry material.

[0062] An axial steel structural member 6 that is centrally positionedextends through the column.

[0063] Typically about 10 mm of mortar separates the wedges 4 from theadjacent blocks 2. The interior of the course is filled with a settablematerial which is concrete 8. In the embodiment of FIG. 2 the wedges 4are offset radially inwardly from the blocks thereby producingdecorative vertical channels in the finished column 10. As will beexplained, the courses may also be formed without this offset so thatthe finished column would not include the vertical channels but wouldhave a smoothly curving outer surface.

[0064] Referring now to FIG. 3 there is shown an apparatus or “cage” 20for forming the column of FIG. 1. Cage 20 comprises a number of rings 22supported by a plurality of longitudinal members 24. Apart from the topand bottom rings the ring spacing corresponds to the height of eachcourse of column 10, that is the dimension “B” of the blocks and wedgesshown in FIGS. 1A and 1B. The top and bottom rings of cage 10 arelocated closer to their neighbouring rings as will be explained furthershortly.

[0065] At FIG. 4 there is shown a plan view of the cage 20. Each ring 22comprises two hinged portions 26 and 28 including hinges 30 and 32.Portions 26 and 28 are bolted together at flanges 36 and 34 by means ofbolts. Nineteen longitudinal members 24 comprising, for example steelrods of square cross-section, are welded or otherwise attached, forexample by riveting, to the inner periphery of the rings 22. The rods 24are spaced in order to align the blocks and wedges that will be used toconstruct a column. They therefore have a function of positioning theblocks relative to each other and to the rings 22. The rods 24 also actto indent the wedges.

[0066] With reference to FIG. 5 there is shown a plan view of cage 20around a completed column 10. It will be noted that the inner surface ofring 22 prevents blocks 2 from falling out of the column prior tosetting of the concrete 8. Other settable materials apart from concretemay also be suitable. Longitudinal members 24 act to hold blocksvertical and retain wedges 4 from falling outwards from the cage. Itwill be noted that a longitudinal member is omitted from the positionindicated at 38. This is to make it easier for a blocklayer to insertblocks and wedges into the cage through the resulting gap, when formingthe courses.

[0067] The members 24 may optionally be designed so that the ringspacing can be adjusted. This will be discussed in more detail belowwith reference to FIG. 10.

[0068] Referring again to FIG. 5, in use cage 20 is mounted in aposition where a column 10 is to be erected such as on a base (FIG. 1).Typically internal column structural member 6 is already in place andthe cage 24 is placed around the structural member by undoing either setof bolts so that the cage may be opened and placed about member 6. Aspreviously mentioned clips or other removable fixing means may be usedin place of bolts and flanges. Preferably the uppermost ring is boltedto the top of member 6 to stabilise the cage. If required, otherstabilisation methods are also possible, such as tethering of the cageto pegs fixed in the surrounding ground.

[0069] A first course of blocks and wedges is then formed to produce anarrangement as shown in FIG. 5. The lowermost ring 22 of cage 20 isspaced from the next ring a distance such that the upper limit of thefirst course is situated halfway up the wall of the second ring. Apartfrom the uppermost ring, subsequent rings are then spaced apart theheight of a course so that each course ends halfway up the wall of theassociated ring. The uppermost ring is half a ring-height closer to thering beneath it, so that the uppermost course of blocks ends flush withthe top of the uppermost ring. After arranging and mortaring the wedges4 and blocks 2 in position, with the assistance of the rings andlongitudinal members 22, 24 as positioning and retaining guides, theinterior of the course is filled with concrete which acts to push thewedges 4 and blocks 2 out against the rings and retaining members 22,24. Consequently the cage 20 facilitates the accurate and regulararrangement of the blocks and wedges in order to form a column such asthat shown in FIG. 1.

[0070] Once the first course has been laid a second course is formedupon it with the guidance of a further retaining ring 22 and thelongitudinal members 24. A mortar layer separates the adjacent courses.After the blocks and wedges of each layer have been mortared into placethe internal void is filled with concrete. The process is continueduntil the column is completed.

[0071] Preferably after sufficient time has been left for the concreteand mortar to set, cage 20 is removed from the newly formed column. Inorder to remove the cage the bolts securing each of the two halves ofeach ring together are unfastened. Each half of the cage is then pivotedabout the hinges of the rings thereby freeing longitudinal members 24from the column. The two halves of the cage 20 are then removed leavingthe column 10 in place.

[0072] It is convenient that a cage be formed in two hinged portions inorder that longitudinal members 24 may be readily swung free of thevertical channels of the column which are formed by the offsetting ofthe wedges.

[0073] If it is desired to construct a very tall column then the cagemay, be used to initially form a first lower stage of the column andthen be raised to form a subsequent stage. This procedure avoids thenecessity of having a cage of unwieldy length. Alternatively a cage ofincreased height or length may be provided. This can be done fairlyeasily by adding additional modules of cage structure to create theadditional length.

[0074] Using ten standard size blocks, which, with reference to FIG. 1Ahave dimensions of A=110 mm, B=230 mm and C=76 mm and ten wedges acolumn with an outer diameter of 570 mm will result. The cage of FIG. 5is designed for production of a such a column. It will be understoodthat larger numbers of blocks and wedges may be used in each course inorder to produce columns with larger diameters if required. In each casea cage of suitable diameter and number of rods or spacers will berequired.

[0075] It will be realised that in the embodiments of the cage discussedthus far the depth to which a building component such as wedge 4 hasbeen indented relative to adjacent building block 2 has depended on thedimensions of longitudinal rods 24. An embodiment of the apparatus inwhich the distance between adjacent rings and the indentation depth isadjustable will be explained with reference to FIGS. 7 to 11.

[0076] In the event that it is desired to produce a column in whichwedges 4 are not indented from blocks 2 then the rods 24 may be reducedin cross section so that wedges 4 may be placed between them and againstthe inner wall of ring 22. This situation is illustrated in FIG. 5Awhere rods with a width of 8 mm have been used. In that case mortarjoints of approximately 10 mm result between adjacent wedges and blocks.

[0077] A portion of an alternative construction of the cage is shown inFIG. 6. In the interests of clarity some of the hinges 30, 32 andretaining bolts and flanges 36 shown in FIG. 5 have been omitted fromFIG. 6. It will be noted that indenters 23 are positioned around theinner wall of the ring 22 at the positions occupied by rods 24 in theembodiment of FIG. 3. Indenters 23 comprise short rod sections that arepreferably dimensioned so that they are shorter than the height or widthof the rings. By so dimensioning the rods an offset between their upperand lower limits and the upper and lower edges of the rings is produced,preferably of about 5 mm. This offset, while not essential, acts as anaid to bricklayers when positioning blocks about the rings. The rings 22are interconnected by means of longitudinal members 37. An advantage ofthe cage of this embodiment is that it affords bricklayers ready accessto the interior of the rings in order to facilitate easy placement ofblocks and wedges during column construction.

[0078] In FIGS. 7 to 11, there is depicted a plan view of a cageaccording to a further embodiment. The cage includes rings 40, theuppermost one of which is visible in FIG. 7. Adjacent rings 40 areinterconnected by longitudinal members 42 in the form of U-channelslocated on the outside of the rings. FIG. 8 illustrates a close-up viewof region “A” identified in FIG. 7.

[0079] Each ring 40 is made up of two identical semicircular portionswhich are bolted or clipped together at flange pairs 44 and 46.

[0080] A radial portion of a ring is depicted in FIGS. 10 and 11. Itwill be noted that paired slots 54, 56 are present in the portiondepicted. The inner wall of each slot is lipped to engage a square nut.The arrangement of slots depicted continues around the circumference ofthe ring. Adjustable indenters 48 are slideable about each groove. Theindenters are each comprised of square nut 52, screw 50 and wing nut 58(visible in FIG. 8). Screw 50 may be rotated to vary its depth ofinsertion through bolt 52. Once the desired depth is achieved the screwis locked in place by tightening wing-nut 58 against the outer surfaceof the ring. By providing paired grooves at different levels each withan indenter it is possible to vary the indentation of wedges of adjacentcourses of a column formed with the aid of the cage.

[0081] With reference to FIG. 9, U-channels 42 include a series oflongitudinally spaced slots 60. As shown in FIG. 8, each ring isattached to the U-channels by means of bolts 62 and wing-nuts 64. Thebolt heads 62 may be accommodated in the lipped slots 56, 54 so that thehead of each bolt does not protrude into the circle defined by the innercircumference of the rings. Alternatively countersunk holes may beformed into the ring for bolts 62. For the purposes of stability andaccuracy it is preferable that at least four equally spaced U-channelsbe used to space the rings as is shown in FIG. 7.

[0082] The finished column may be left with the blocks exposed as shownin FIG. 1, or may be covered with a render to produce a stonework orstucco, or other desired, finish. Finishes suitable for application tobrickwork are well known in the field of building and so will not bediscussed in detail here.

[0083]FIG. 12 illustrates a cage that is adapted to make columns ofnon-uniform cross-section. Unless otherwise indicated the same referencenumerals will be used to refer to the same components.

[0084] Typically such columns taper outwardly and then inwardly alongtheir length with an hour glass or undulating profile. Mexican stylecolumns in particular embody this stylisation.

[0085] The cage 20 comprises broadly a plurality of spaced longitudinalmembers 24. In the illustrated version there are four said members 24spaced equidistantly apart from each other and surrounding a pluralityof rings 22. The rings 22 are positioned at spaced intervals along thelength of the members 24.

[0086] Different rings 22 have different diameters. As one progressesfrom the top of the cage in a downward direction the rings decrease indiameter up to a point three rings down where the diameter is at aminimum. Further down the cage the diameter of the rings increase insteps to a maximum diameter six rings down. The rings then decrease oncemore in diameter to the bottom of the cage.

[0087] Each of the rings of less than maximum diameter is held in placeby support arms 27 extending radially from each longitudinal member tothe associated ring 22. The support arms 27 comprise a bolt that ispassed through the ring, then through a spacer spacing the longitudinalmember from the ring, and then through an aperture, eg a slot aperture,in the longitudinal member. The bolt has a screw thread formationtowards its free end over which a nut defining a complementary screwthreaded bore, eg a wing nut, is passed. The wing nut is manuallytightened onto the free end of the bolt to hold the assembly tightly andsecurely together.

[0088] The rings 22 of different diameter are accommodated by havingbolts and spacers of different lengths. For example the third ring downfrom the top of the column has longer support arms than the ringimmediately above it. The ring at the top of the cage has no supportarms to speak of. The ring is mounted directly onto the longitudinalmembers 24 by means of a bolt and associated wing nut.

[0089]FIG. 13 shows another cage having rings of different diameterforming the column of non-uniform cross-section. This cage is avariation on that shown in FIG. 12.

[0090] Broadly the cage 20 comprises three rings 22 supported by aplurality of longitudinal members 24. Most of the rings comprise anouter ring element 26 having a diameter that positions it in proximityto the longitudinal members for attachment thereto, and an inner ringelement 25 spaced radially in from the outer ring element 26.

[0091] Different inner ring elements have different diameters. Thediameter of the inner ring element 25 at any particular point on thecolumn is determined by the diameter of the column design at thatparticular point.

[0092] Each inner ring element 25 is attached to and supported by itsassociated outer ring element 26 by means of a plurality of support arms27. Each support arm is rigid and extends between the inner and outerring elements. Generally there will be at least two said support arms 27supporting each inner ring element 25. In the illustrated embodimentthere are four said support arms 27 supporting each inner ring element25 spaced equidistantly around the circumference of the column.

[0093] While most rings comprise an inner and outer ring element, someof the rings may comprise only a single ring element. These pointscorrespond to the points along the column having maximum diameter. Inthe illustrated embodiment the middle ring is such a ring.

[0094] The support arms 27 are typically constructed such that the innerring element 25 is detachable from the outer ring element 26.

[0095] An exploded view of the support arms 27 is shown in the drawings.It comprises a bolt 28 having a head which is passed in an outwarddirection through an aperture in the inner ring element 25 from theinner side thereof, then through a spacer 29 that spaces the inner andouter ring elements the correct distance apart, and then through anaperture in the outer ring element 26 and through an aperture in thelongitudinal member. The free end of the bolt has a screw threadformation defined thereon and a nut 67 having a complementary screwthreaded bore defined therein is passed over the free end of the bolt.Typically the nut 67 is a wing nut which can be manually tightened by anoperator. This tightening urges the longitudinal member 24 onto theouter ring 22 and the other components thereby clamping all thecomponents tightly and securely together.

[0096] When using the cages 20 illustrated in FIGS. 12 and 13, theindividual blocks are tapered in a longitudinal direction along one sidethereof so as to reproduce the desired tapering profile of the column.Each of the blocks that is to be used in building the column of varyingcross-section is tapered or shaped before it is placed in the cage 20.This is accomplished by removing or cutting material away from one sideof a blank having a rectangular block shape. Various jigs and templatescan be used to assist in removing this material from the blocks to formthe correct shape. One particularly preferred apparatus for achievingthis task is illustrated in FIGS. 16 to 18.

[0097] In FIGS. 16 to 18 the apparatus generally is indicated byreference numeral 70. In FIG. 16 the apparatus 70 comprises broadly asupport 71 having two members 72, 73 extending upwardly therefromparallel to each other and spaced apart from each other. The upper edgesof the members 72, 73 have a shape that defines a profile correspondingto the required taper of the block. These upper edges of the membersalso define rails or guide formations 74, 75 along which a cutting orsanding tool is displaced. The apparatus also includes clamping meansindicated generally by numeral 76 for clamping a block indicatedgenerally by reference numeral 80 firmly between the two members 72, 73and clamping the members 72, 73 to each other to form a single assembly.In the illustrated embodiment the clamp comprises a plurality of screwthreaded bolts over which manually rotatable wing nuts are passed.

[0098] The block 80 illustrated in the drawings is an elongate blockthat is typically made of HEBEL. Typically the block will have a lengthof 1.2 metres. Further the block 80 has a trapezoidal shape incross-section which may loosely be described as a wedge. One side of theblock namely the outer side 81 is wider than the inner side 82 which isan inner side. The block 80 as a whole has a constant cross-sectionalong its length.

[0099]FIG. 17 shows the block 80 tightly clamped between the members 72,73. While the apparatus in FIG. 19 is different it shows how the wedgeshaped block may be clamped in the apparatus between members 72, 73. Italso shows a sanding tool 84 for removing excess material on said outerside 81 of the block 80 projecting up above the upper edges or rails 74,75 of the members 72, 73. The sanding tool 84 may conveniently be asanding tool of the type that is bought off the shelf. It comprises asanding element 85 which is moved at high speed and which is broughtinto contact with the surface to be sanded and two handle formations 86.

[0100] The tool 84 does however have one modification to adapt it foruse with the apparatus described above. The modification comprises theaddition of two front wheels 87 and two rear wheels 88 spacedlongitudinally apart from each other on the tool. The front and rearwheels 87 and 88 travel along the rails 74, 75 formed by the upper edgesof the members 72, 73. This travel of the wheels 87, 88 along the rails74, 75 guides the sanding tool 85 along a complementary path and shapesthe profile of the block in the desired form.

[0101] In use the sanding tool 84 is energised and is then passed overthe outer end 81 of the block 80 so that, at least when the block 80 isworn down, the wheels 87, 88 travel along the rails 74, 75. This removesexcess material from the block 80 and produces a block 80 having thedesired profile. The travel of the wheels 87, 88 along the railsprovides a system for reliably and reproducibly producing the desiredprofile in the block to the required tolerances The tool 84 is manuallypushed along the rails by an operator gripping the tool 84 by thehandles 86 provided for this purpose.

[0102]FIG. 18 shows how the outer side 81 of the block 80 has beenshaped appropriately to conform with the profile defined by the upperedges or rails 74, 75 of the members 72, 73. This apparatus thereforeprovides an efficient and reliable way of accurately shaping all of theblocks 80 to be used in the column with the correct shape.

[0103]FIG. 19 shows a variation on the apparatus shown in FIGS. 16 to18. The block 80 is clamped between the rails 72, 73 and the rails 74,75 are formed by a pair of members spaced outwardly of the members 72,73. In this version the wheels travel along the rails that are spacedoutwardly of the block. FIG. 19 also shows how the wedge of thetrapezoidal cross-section is clamped in position between the parallelextending members 72, 73.

[0104] Applicant also points out that the blocks used in FIGS. 16 to 18are considerably longer than the blocks used in the column of FIG. 1 andillustrated in FIGS. 1a and 1 b. The blocks in these drawings would havea length at least three times that of the blocks illustrated in FIG. 1The blocks 80 illustrated in FIG. 16 typically have a length of about1.2 metres. An obvious advantage of using longer blocks is that thenumber of courses provided to produce a column of given height isreduced and therefore the manual labour involved in producing a columnis substantially reduced.

[0105] Applicant has found that HEBEL is a convenient material to use inthe formation of the columns, HEBEL is a building material that can besupplied in sections having a suitable square rectangularcross-sectional profile. The blocks are then cut by a saw to produce awedge shaped cross-section as shown in FIG. 16. The sections areprovided in lengths of 2.4 metres. These are cut into two blocks eachhaving a length of 1.2 metres.

[0106] The apparatus can be used to cut blocks for a large variety ofcolumns having different profiles. A block 80 having a different profilemay be cut by simply removing the members 72, 73 shown in the drawingsand replacing them with new members having a different profile. In factthe apparatus may include a number of sets of members 72, 73 each havingdifferent profiles corresponding to different designs of columns ofvarying cross-section. The operator then selects the set of membershaving the appropriate contour or shape for the particular design to bebuilt and mounts these on the support 71. The blocks are then cut in themanner described above.

[0107]FIGS. 14A and 14B show yet another cage suitable for producing acolumn of constant cross-section. This column is structurally andfunctionally very similar to the column illustrated in FIG. 3.Accordingly the following description will focus on the features of thiscolumn that are different to that of the column in FIG. 3.

[0108] The cage broadly comprises a set of four longitudinal members 24spaced apart from each other around the circumference of the column thatare interconnected by a plurality of transverse retaining members 22. Inthe illustrated embodiment there are three said retaining members 22which are rings spaced apart from each other. One is positioned towardsthe top of the column, one towards the bottom of the column, and anintermediate ring is positioned mid way up the height of the column.

[0109] Each longitudinal member 24 comprises a U-shaped channel sectionopening outwardly and having a web portion that is attached to the ringsor retaining members 22. Each member has a plurality of apertures, egslot apertures, defined therein through which one or more bolts can bepassed to attach the longitudinal members 24 to the rings 22.

[0110] Each ring 22 comprises two half circle ring elements 91, 92 whichoverlap each other at each end and are attached to each other via theoverlapping ends. Each ring element 91, 92 has a plurality of pairs ofapertures 93 defined therein at spaced intervals around itscircumference.

[0111] As illustrated in some detail in FIG. 15 the overlapping ends ofthe elements 91, 92 are attached to each other by passing a locatingelement 94 having pins 95 through the pairs of apertures which arealigned in both elements to attach them together. This attachmentmechanism is in some respects analogous to the attachment of ends of abelt. The pairs of apertures 93 on the two elements 91, 92 are alignedand then the pins are passed through both elements 91, 92 to attach themtogether.

[0112] Further the locating elements 94 with pins 95 are also passedthrough the remaining apertures in the ring element The pins 95 projectthrough the ring elements 91, 92 into the space defined by the rings 22and correctly position the blocks 80 within the cage 20. Each block 80is positioned with such a pin 98 on either side thereof in the spacebetween the block and the adjacent block. This way the blocks 80 areaccurately positioned on the column to form a precise and symmetricalcolumn.

[0113] The pins 95 of the locating elements 94 that attach the two ringelements 91, 92 to each other also perform this function of locating andaligning the individual blocks within the column, Therefore theseparticular elements 94 perform two functions, namely attaching the twoelements to each other and locating the blocks with respect to eachother and the cage.

[0114] In FIGS. 14A and 14B the pole or member around which and ontowhich the column is built has deliberately not been shown with fulldetail to keep the illustration as simple as possible.

[0115] In use the cage is constructed by attaching two longitudinalmembers 24 to three ring elements 91, 92 to form a half cage. Two halfcages are then attached to each other by passing the pins 95 of thelocating elements 94 through the overlapping ends of the ring elements91, 92 as described above. This attachment is illustrated in some detailin FIG. 15. This produces an assembled cage ready for use in forming acolumn. The cage is mounted around the pole or elongate member that isnot shown in detail in the illustration.

[0116] The column construction process is commenced by placing blocks 80sequentially into the column to form a lower course of blocks extendingbetween the bottom ring and the intermediate ring. Each block is placedcarefully in position with the pins of the adjacent locating elements oneither side thereof. The space between the adjacent blocks is filledwith a settable material, eg mortar. Once the first course has beenbuilt up the interior space defined by the blocks is filed with asettable material, eg concrete, to form a solid column.

[0117] In FIG. 14 some of the blocks have longitudinal grooves in theirouter surfaces, These provide fluting on the outer surface of the columnwhich is an optional aesthetic feature.

[0118] As shown in FIG. 14B the process is then repeated for a secondcourse of blocks.

[0119] In the illustrated embodiment each block has a length of 1.2metres and the column that is built has a height of 2.4 metres. Ifadditional height is required for the column to be erected then a cageof increased height is provided and a column having more courses isbuilt up in the same way as described above.

[0120] An advantage of the method and apparatus described above is thatthe components forming the cage is very simple and can be easilytransported to a building site and then assembled on site. The cage isassembled with a length that corresponds to the height of the column tobe built. The column can then be manufactured on site and used to forman integral column of a building. This way the formed column does notneed to be transported to the actual building site. This avoids thecomplexity and attrition that one would expect in transporting such acolumn over large distances. Despite the simple manufacturing procedurethat is carried out on the site a finely engineered column having closetolerances is produced and that will satisfy the most discerningcustomer. Yet further the method and apparatus provides a flexibility incolumn height. The cage is formed with the appropriate length on siteand a column having this height is then built The column is simply builtto the desired height whatever that may be This is simply not possiblewith precast products.

[0121] Further the column illustrated in FIG. 14B comprises only twocourses of blocks and as such can be manufactured fairly rapidly using aminimal amount of labour. The advantages of the reduction in labour costusing blocks of the size illustrated in FIG. 14 are obvious.

[0122] While the cages described above have been of circularcross-section it is also possible to produce cages having square ringsin order to form columns of square cross section. Square cross sectioncolumns do not require the incorporation of wedges but only of regularblocks. Polygonal rings may also be used in order to produce columns ofpolygonal cross-section.

[0123] It will of course be realised that the above has been given onlyby way of illustrative example of the invention and that all suchmodifications and variations thereto as would be apparent to personsskilled in the art are deemed to fall within the broad scope and ambitof the invention as is herein set forth.

1. A column for a building or structure, the column including: aplurality of courses of blocks, each course comprising a plurality ofblocks arranged in the form of a closed figure forming a peripheralsurface of the column and defining an interior space radially inwardlyof the blocks, wherein each block has a longitudinal axis that issubstantially parallel to the longitudinal axis of the column, andwherein the interior space is filled with a settable material that hasbeen introduced into the space and then allowed to set, and wherein theblocks are also adhered to each other by a settable material.
 2. Acolumn according to claim 1, wherein the blocks are adhered to eachother by being mortared to each other by a cementitious material, andthe settable material in the interior space is also a settablecementitious material.
 3. A column according to claim 1, wherein eachblock has an upper end and a lower end, and the upper ends and the lowerends of all blocks in each course are substantially aligned with eachother.
 4. A column according to claim 1, wherein the blocks are formedwith between one and three different basic configurations, and whereineach of the blocks having the same basic configuration has substantiallythe same size and shape.
 5. A column according to claim 4, whereinsubstantially all of the blocks arranged in the closed figure have awedge-shaped block configuration.
 6. A column according to claim 1,wherein the blocks arranged in the form of a closed figure compriseblocks having a rectangular configuration alternating with blocks havinga wedge-shaped configuration.
 7. A column according to claim 6, whereinouter ends of the wedge-shaped blocks are recessed inwardly from outerends of the rectangular blocks so as to define longitudinal channels inthe peripheral surface of the column, or alternatively outer ends of thewedge-shaped blocks are broadly radially aligned with outer ends of therectangular blocks so as to form a substantially smooth peripheralsurface of the column.
 8. A column according to claim 1, furtherincluding an axial member passing through the interior space of thecolumn and projecting out through the ends of the column, and whereinthe column is effectively built onto the axial member.
 9. A columnaccording to claim 1, further including a render coating on theperipheral surface of the column and a base mounted on the lower end ofthe column and a head mounted on the upper end of the column, both thebase and the head projecting radially outwardly of the peripheralsurface.
 10. An apparatus for use in forming a column from a pluralityof courses of blocks, the apparatus including: a plurality of elongatemembers extending longitudinally with respect to the column to be builtand spaced apart from each other around the column to be built; aplurality of retaining members extending transverse to the longitudinalmembers and mounted thereto, the retaining members being spaced apartfrom each other by not more than the length of the blocks such thatthere is at least one retaining member for each course of blocks, theretaining members assisting in vertically aligning and positioning theblocks.
 11. An apparatus according to claim 10, wherein at least some ofthe retaining members are vertically positioned so as to straddle thepoint of separation of adjacent courses of blocks intermediate the endsof the column thereby to assist in the vertical alignment of the courseof blocks above the point of separation and the course of blocks belowthe point of separation.
 12. An apparatus according to claim 10, furtherincluding locating means on each retaining member for correctly locatingthe position of each block in the associated course of blocks relativeto the retaining member and to the other blocks.
 13. An apparatusaccording to claim 12, wherein the locating means comprises a pluralityof rigid elements that are permanently mounted on the inside of eachretaining member.
 14. An apparatus according to claim 12, wherein thelocating means comprises a plurality of pins that are removably insertedthrough each retaining member in a radially inward direction and arepositioned between adjacent blocks of a said course of blocks in thecolumn thereby to correctly position the adjacent blocks.
 15. Anapparatus according to claim 14, wherein each retaining member has saidpins extending through it on each side of each block in the columnwhereby to correctly position all blocks.
 16. An apparatus according toclaim 10, further including indenters for indenting or setting a blockradially inwardly from an adjacent block and also from the associatedretaining member so as to create a column with longitudinal grooves orindentations.
 17. An apparatus according to claim 16, wherein the radialposition of the indenters can be adjusted so as to vary the depth of theoffset and thereby the depth of indentation in the formed column.
 18. Anapparatus according to claim 10, wherein the longitudinal members andretaining members together form a cage, and the retaining members are inthe form of rings having a substantially circular configuration.
 19. Anapparatus according to claim 18, wherein the cage has top and bottomretaining members and also at least one intermediate retaining memberpositioned between said top and bottom retaining members, and the topretaining member is positioned to overly the upper edge of the topcourse of blocks and the bottom retaining member is positioned to overlythe lower edge of the bottom course of blocks, and each intermediateretaining member is positioned to overly the point of separation ofadjacent courses of blocks.
 20. An apparatus according to claim 10,wherein each of the retaining members is slidably mounted on thelongitudinal members so as to be longitudinally slidable at least tosome extent along the length of the longitudinal member.
 21. Anapparatus according to claim 20, wherein each longitudinal member has aslot aperture and each retaining member is attached to each longitudinalmember by passing a bolt through an aperture in the retaining member andthen through the longitudinal slot aperture and then clamping thelongitudinal member to the retaining member by means of a nut passedover the free end of the bolt.
 22. A method of forming a column for usein a building structure, the method including: a. providing a columnforming apparatus as defined in claim 17 and a plurality of blocks; b.positioning the apparatus where the column is to be formed; c. layingone or more courses of blocks in the form of a closed figure forming aperipheral surface of the column and defining an interior space radiallyinwardly of the blocks, the blocks being located by the retainingmembers of the column forming apparatus; and d. filling the interiorspace with a settable material and allowing it to set.
 23. A methodaccording to claim 22, wherein the laying step includes adhering theblocks to each other by mortaring them to each other with a cementitiousmaterial and the settable material that is used lo fill the interiorspace is also a cementitious material.
 24. A method according to claim22, wherein the positioning step comprises locating the apparatus aroundan axial support member, and rigidly mounting the apparatus to the axialmember by means of a stabiliser extending between the apparatus and thesupport member.
 25. A method according to claim 24, wherein thelongitudinal members and retaining members form a cage that can beopened and closed along an axis extending in a longitudinal direction,and the step of positioning the apparatus includes either opening up thecage or else lowering it over the axially extending support member. 26.A method according to claim 22, wherein said column has a plurality ofcourses of blocks and the method comprises laying a first course ofblocks then filling the interior space of the first course with asettable material, and then repeating this procedure of laying thecourse and filling the interior space for succeeding courses of blocksuntil a column of desired height has been formed.
 27. A method accordingto claim 26, further including the step of separating the cage from itsattachment to the support member by removing the stabiliser and thenopening up the cage and moving it out from its position surrounding thecolumn.